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United States Patent | 6,197,219 |
Foulger | March 6, 2001 |
A conductive polymer composite material comprises: a minor phase material comprising a semicrystalline polymer; a conductive filler material dispersed in said minor phase material in an amount sufficient to be equal to or greater than an amount required to generate a continuous conductive network in said minor phase material; and a major phase material, said major phase material being a polymer which when mixed with said minor phase material will not engage in electrostatic interactions that promote miscibility, said major phase material having said minor phase material dispersed therein in an amount sufficient to be equal to or greater than an amount required to generate a continuous conductive network in said major phase material, forming a (semi)conductive ternary composite having distinct co-continuous phases.
Inventors: | Foulger; Stephen H. (Lexington, SC) |
Assignee: | Pirelli Cables and Systems LLC (Columbia, SC) |
Appl. No.: | 307057 |
Filed: | May 7, 1999 |
Current U.S. Class: | 252/500; 174/25C; 174/25R; 174/36; 174/68.1; 174/102R; 252/510; 252/511; 252/518.1; 252/519.32 |
Intern'l Class: | H01B 001/06 |
Field of Search: | 252/500,510,511,519.32,518.1 174/25 R,25 C,36,68.1,102 R |
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4929388 | May., 1990 | Wessling. | |
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5037999 | Aug., 1991 | VanDeusen | 174/36. |
5098610 | Mar., 1992 | Okamura et al. | 252/511. |
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5246783 | Sep., 1993 | Spenadel et al. | 426/961. |
5248553 | Sep., 1993 | Miyashita et al. | 428/297. |
5281757 | Jan., 1994 | Marin et al. | 174/36. |
5556697 | Sep., 1996 | Flenniken | 428/323. |
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European Search Report No. RS 101469 dated Oct. 16, 1998. Graham, Gordon et al., Insulating and Semiconductive Jackets for medium and High Voltage Underground Power Cable Applications, IEEE Electrical Insulation Magazine, vol. 11, No. 5 (Sep/Oct 1995), pp. 5-12. Narkis, Moshe, Structuring and Special Effects in Polymer Systems Containing Carbon Black. Gubbles, F et al., Design of Electrical Conductive Composites: Key Role of the Morphology on the Electrical Properties of carbon Black Filled Polymer Blends, Macromolecules, vol. 28, No. 5 (1995), pp. 1559-1566. Tchoudakov, R., et al., Conductive Polymer Blends with Low Carbon Black Loading: Polypropylene/Polyamide, Polymer Engineering and Science, vol. 36, No. 10 (May 1996), pp. 1336-1346. Kirkpatrick, Scott, Percolation and Conduction, Reviews of Modern Physics, vol. 45, No. 4 (Oct. 1973), pp. 574-588. Lux, F., Review Models Proposed to Explain the Electrical Conductivity of Mixtures Made of Conductive and Insulating Materials, Journal of Materials Science, vol. 28 (1993), pp. 285-301. Sherman, R.D., et al., Electron Transport Processes in Conductor-Filled Polymers, Polymer Engineering and Science, vol. 23, No. 1 (Jan., 1983) pp. 36-46. Narkis, M., et al., Resistivity Behavior of Filled Electrically Conductive Crosslinked Polyethylene, Journal of Applied Polymer Science, vol. 29 (1984), pp. 1639-1652. Narkis, M. et al., Segregated Structures in Electrically Conductive Immiscible Polymer Blends, ANTEC '95, pp. 1343-1346. Breuer, O., et al., Segregated Structures in carbon Black-Containing Immiscible Polymer Blends: HIPS/LLPDE Systems. Levon, Kalle, et al., Multiple Percolation in Conducting Polymer Blends, Macromolecules, vol. 26, No. 15 (1993) pp. 4061-4063. Gubbels, F., et al., Design of Electrical Conductive Composites: Key Role of the Morphology on the Electrical Properties of Carbon Black Filled Polymer Blends, Macromolecules, vol. 28, (1995) pp. 1559-1566. Gubbels, F., et al., Selective Localization of Carbon Black in Immiscible Polymer Blends: A Useful Tool to Design Electrical Conductive Composites, Macromolecules, vol. 27, No. 7 (1994), pp. 1972-1974. Kozlowski, M., Electrically Conductive Structured Polymer Blends, Polymer Networks & Blends, vol. 5, No. 4 (1995), pp. 163-172. Tang, H., et al., Electrical Behavior of Carbon Black-Filled Polymer Composites: Effect of Interaction Between Filler and Matrix, Journal of Applied Polymer Science, vol. 51, No. 7 (Feb. 1994), pp. 1159-1164. |
TABLE 1 Constituent Tradename Characteristics Producer EVA Levapren 450 45 weight % VA content Bayer Corporation HDPE Petrothene LS6081-00 Density = 0.963 g/cm.sup.3 Millennium Chemical CB Vulcan XC72 N.sub.2 Surface Area = 254 m.sup.2 /g Cabot Corporation DBP oil absorption = 174 cm.sup.3 /100 g mean particle diameter = 300 .ANG.
TABLE 2 Constituent (w/w) M.sub.0 M.sub.5 M.sub.10 M.sub.15 M.sub.20 M.sub.25 M.sub.30 M.sub.35 M.sub.40 M.sub.45 M.sub.50 M.sub.100 EVA 100.0 95.0 90.0 85.0 80.0 75.0 70.0 65.0 60.0 55.0 50.0 0.0 HDPE 0.0 4.4 8.8 13.2 17.6 22.0 26.4 30.8 35.2 39.6 44.0 88.0 CB 0.0 0.6 1.2 1.8 2.4 3.0 3.6 4.2 4.8 5.4 6.0 12.0
TABLE 3 Composite Volume Resistivity (.OMEGA. .multidot. cm) Unfilled HDPE 2.348 .times. 10.sup.17 M.sub.0 (Unfilled EVA) 2.188 .times. 10.sup.14 M.sub.5 2.211 .times. 10.sup.14 M.sub.10 1.562 .times. 10.sup.14 M.sub.15 9.343 .times. 10.sup.13 M.sub.20 7.576 .times. 10.sup.13 M.sub.25 6.874 .times. 10.sup.13 M.sub.30 2.288 .times. 10.sup.13 M.sub.35 6.700 .times. 10.sup.5 M.sub.40 2.226 .times. 10.sup.3 M.sub.45 1.416 .times. 10.sup.3 M.sub.50 4.360 .times. 10.sup.2 M.sub.100 6.490 .times. 10.sup.1